Airflow control and heat recovery in a managed kiln

ABSTRACT

A controlled kiln and manufacturing system for biochar production includes control systems and subsystems. An example biochar kiln exhaust apparatus, includes a chimney configured for heating by pyrolysis and for exhausting smoke from the combustion chamber. The example biochar kiln exhaust apparatus also includes a plurality of exhaust inlet pipes configured to pass smoke from the combustion chamber to the chimney.

PRIORITY CLAIM

This application is a divisional of U.S. patent application Ser. No.14/384,351 filed Sep. 10, 2014 titled “Airflow Control and Heat RecoveryIn A Managed Kiln” of Aupperle et al., which is a 371 National StageEntry of PCT Patent Application No. PCT/US13/30079, which claims thepriority benefit of U.S. Provisional Patent Application Nos. 61/609,336filed Mar. 11, 2012 for “Ventilation and exhaust system for a biocharkiln” and 61/639,623 filed Apr. 27, 2012 for “Biochar heat recoveryprocess.” This application is also related to PCT Patent Application No.US13/25999 filed Feb. 13, 2013 for “Controlled kiln and manufacturingsystem for biochar production” as a continuation-in-part patentapplication in the United States and any other country whose patent lawrecognizes CIP status; the PCT Patent Application further claims thepriority benefit of U.S. Provisional Patent Application Nos. 61/599,906filed Feb. 16, 2012 for “Biochar kiln with catalytic converter,”61/599,910 filed Feb. 16, 2012 for “Process completion detection forbiochar kiln,” and 61/604,469 filed Feb. 28, 2012 for “Biocharmanufacturing process.” Each of the applications cited above areincorporated by reference in their entirety as though fully set forthherein.

BACKGROUND

Biochar is made from biomass (trees, agricultural waste, etc.) in anoxygen-deprived, high temperature environment. Quality biochar has highpurity, absorptivity and cation exchange capacity which providesignificant benefits to several large markets including agriculture,pollution remediation, odor sequestration, separation of gases, oil andgas clean up, and more.

SUMMARY

Airflow control and heat recovery in a managed kiln is disclosed. In anexample, a ventilation and exhaust system for a biochar kiln comprises aplurality of air inlet ports around an outer circumference of acombustion chamber. A chimney is configured for heating by pyrolysis andfor exhausting smoke from the combustion chamber. A plurality of exhaustinlet pipes are configured to pass smoke from the combustion chamber tothe chimney. A controller is configured to regulate the exhausting basedupon output from one or more sensors.

The example system may further comprise at least one catalytic converterconfigured to reduce emissions from smoke exhausting through thechimney. Port covers may be configured to open and dose the air inletports to respectively allow air to enter the combustion chamber andprevent air from entering the combustion chamber. The port covers mayhave cams configured to compress port cover seals against the air inletports with rotation in a first direction. Flow regulation assemblies maybe coupled with the port covers and wherein the flow regulationassemblies include blowers. The controller is configured toindependently operate a plurality of valves to regulate flow through theair inlet ports based upon the output from the one or more sensors.

In another example, a biochar kiln exhaust apparatus, comprises achimney configured for heating by pyrolysis and for exhausting smokefrom the combustion chamber. A plurality of exhaust inlet pipes areconfigured to pass smoke from the combustion chamber to the chimney. Atleast one catalytic converter may be operatively coupled with thechimney for reducing emissions from smoke exhausting through thechimney. A damper assembly may be coupled with the chimney andconfigured to regulate exhaust flow. A first forced air inlet may beoperatively coupled with the chimney to control operating condition(s)of the at least one catalytic converter. A second forced air inlet maybe operatively coupled with the chimney to control operatingcondition(s) of the at least one catalytic converter. The first andsecond forced air inlets may be used one instead of the other and/or incombination with other air inlets and/or other air flow controls.

In another example, a heat recovery system may comprise at least onebiochar kiln having a combustion chamber. A chimney having proximal anddistal ends is configured to exhaust smoke from the combustion chamberbetween the proximal and distal ends. A heat exchanger may be configuredto recover heat from the chimney and provide the heat to a secondarysubsystem. The secondary subsystem can be, by way of non-limitingexample, one or more of an oil sands production water heater, a buildingheater or a water condenser. A controller may be configured to maintainan optimal mixture of smoke and air in the chimney.

The heat recovery system may comprise at least one catalytic converteroperatively coupled with the chimney to incinerate exhaust and increasechimney temperature near the distal end. At least one sensor may beconfigured to provide information about operating conditions to thecontroller. The at least one sensor may be configured to sense at leastone of: an exhaust temperature, a catalytic converter temperature and aheat exchanger temperature.

In another example, a heat recovery apparatus comprises a chimneyconfigured to exhaust air and smoke from a biochar kiln combustionchamber. At least one catalytic converter is operatively coupled withthe chimney to reduce exhaust smoke emissions. A heat exchanger isconfigured to recover heat from the chimney and provide the heat to asecondary application. The heat exchanger may be configured to exchangeheat from one volume of air to another volume of air. The heat exchangermay be configured to exchange heat from a volume of air to a volume ofliquid. The heat exchanger may be configured to exchange heat from avolume of air to a volume of steam.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side perspective view of an example managed orcontrolled kiln usable by itself or as part of a biochar productionplant.

FIG. 2 illustrates a bottom view of the example controlled biochar kilnof FIG. 1.

FIG. 3 illustrates a partial cut-away of a side perspective view of theexample controlled biochar kiln of FIGS. 1 and 2.

FIG. 4 illustrates a cut-away side perspective view of the examplecontrolled biochar kiln of FIGS. 1-3 emphasizing an internal combustionchamber.

FIG. 5 illustrates a top view of the example controlled biochar kiln ofFIGS. 1-4 emphasizing an internal combustion chamber.

FIG. 6 illustrates a cut-away side perspective view of the examplecontrolled biochar kiln of FIGS. 1-5 emphasizing a chimney component.

FIG. 7 illustrates a top view of the example controlled biochar kiln ofFIGS. 1-5.

FIG. 8 illustrates an example automated handler engaging a biochar kilnduring transport of the kiln from one station of a production plant toanother.

FIG. 9 illustrates a detail view of an example of a lid stack plate foruse with the example biochar kiln of FIGS. 1-8 & 25-28.

FIG. 10 illustrates a perspective section view of an example catalyticconverter for use with the example biochar kilns of FIGS. 1-8 & 25-28.

FIG. 11 illustrates a high-level schematic diagram of an example monitorand control subsystem.

FIG. 12 illustrates an example flow diagram of a process for monitoringand controlling conversion of feedstock into biochar.

FIG. 13 illustrates a perspective view of an example sealing cover foruse with the example biochar kiln of FIGS. 1-7.

FIG. 14 illustrates an exploded view of the sealing cover of FIG. 9.

FIG. 15 illustrates a side perspective view of a first example of airinlet port flow regulation assembly coupled with an air inlet port 240.

FIG. 16 illustrates a side perspective view of the example flowregulation assembly of FIG. 15 decoupled from air inlet port 240.

FIG. 17 illustrates a side perspective view of the example flowregulation assembly of FIGS. 15 & 16 without blower 590 and heat shield567.

FIG. 18 illustrates a partial cut-away side perspective view of theexample flow regulation assembly of FIGS. 15-17.

FIG. 19 illustrates another partial cut-away side perspective view ofthe example flow regulation assembly of FIGS. 15-18.

FIG. 20 illustrates yet another partial cut-away side perspective viewof the example flow regulation assembly of FIGS. 15-19 with supportbracket 565 removed.

FIG. 21 illustrates a partial section view of the first example flowregulation assembly of FIGS. 15-20.

FIG. 22 illustrates a partial section view of a second example air inletport flow regulation assembly.

FIG. 23 illustrates a side perspective view of a third example air inletport flow regulation assembly coupled with air inlet port 240.

FIG. 24 illustrates a side perspective view of the example flowregulation assembly of FIG. 23 decoupled from air inlet port 240.

FIG. 25 illustrates a partial cut-away side perspective view of theexample flow regulation assembly of FIGS. 23 & 24.

FIG. 26 illustrates another partial cut-away side perspective view ofthe example air inlet port flow regulation assembly of FIGS. 23-25.

FIG. 27 illustrates a partial section view of the example air inlet portflow regulation assembly of FIGS. 23-26.

FIG. 28 illustrates another partial cut-away perspective view of theexample air inlet port flow regulation assembly of FIGS. 23-27.

FIG. 29 illustrates a cut-away side perspective view of a biochar kilnwith an first example exhausting system.

FIG. 30 illustrates a cut-away side perspective view of a biochar kilnwith a second example exhausting system.

FIG. 31 illustrates a side view of the biochar kiln of FIG. 26.

FIG. 32 illustrates another side view of the biochar kiln of FIGS. 26 &27.

FIG. 33 illustrates a biochar kiln including an example heat exchangeroperatively coupled with an exhaust system.

FIG. 34 illustrates a flow diagram of an example exhausting process.

FIG. 35 illustrates a flow diagram of a first control step of an exampleexhausting process.

FIG. 36 illustrates a flow diagram of a second control step of anexample exhausting process.

FIG. 37 illustrates a flow diagram of a third control step of an exampleexhausting process.

FIG. 38 illustrates a flow diagram of an example heat recovery process.

DETAILED DESCRIPTION

When char is produced from biomass feedstock, the char is referred to as“biochar.” The biochar described herein is a unique carbon productcreated in a low oxygen or oxygen-deprived, high-heat environment.Limited oxygen prevents combustion and instead of simply burning thebiomass, converts the biomass to a structured biochar product exhibitingspecial physiosorptive and/or chemisorptive properties. The biocharproduct is a high-carbon, fine-grain product of pyrolysis (i.e., thedirect thermal decomposition of biomass in a deprived oxygen environmentto yield biochar products).

The relative quality and quantity of biochar product yielding frompyrolysis varies with process conditions (e.g., temperature). Forexample, pyrolysis controlled temperatures tend to produce a higherquality biochar, while erratic temperatures tend to yield unfinishedproduct, more smoke, and/or more undesired liquid and gas emissions.Other process parameters also affect characteristics of the biocharproduct. For example, low temperatures may provide higher yields, butmay also reduce the adsorption capacity of the biochar.

The biochar product may have very high adsorption capabilities (e.g., anaffinity for vapor and aqueous phase molecules). The biochar may alsopossess cation and/or anion exchange capabilities that attract andsequester molecules, providing unique benefits. For example, markets forthe biochar include, but are not limited to, agriculture uses, odorcontrol, animal feed supplements, removal of mercury, heavy metals,toxins, organics, and/or other contaminants from industrial processes(e.g., coal power plant stack emissions or waste water such as thatderived from oil and gas production and drilling), mitigation of oilspills, removal of excessive fertilizer from field run offs,sequestration of e-coli, phosphorus and other contaminants from drinkingwater, and containment of mine tailing contaminants, to name only a fewexamples.

The biochar product is also a stable solid which can endure in soil formany years. As such, the biochar product can be used to sequesterfertilizer nutrients and water, which reduces leaching of nutrients fromthe soil and makes nutrients more readily available to plants. Thebiochar product can be used as a soil amendment or additive to improvecrop yield, improve water moisture availability, reduce soil emissionsof nutrients and greenhouse gases, reduce nutrient dispersion andleaching, improve soil pH, and reduce irrigation and fertilizerrequirements. Biochar used in soil also helps reduce the use ofexternally applied fertilizers, thereby reducing cost and emissions fromfertilizer production and transport. In addition, biochar enhances soilsso that the same soil can be used potentially indefinitely to sustainagriculture. Biochar also provides soil microbial domiciles to protectthe microbes from predators and weather (e.g., rains, drainage, anddrought).

The biochar product can also be used to decrease fertilizer run-off byoperation of the same sequestration mechanism. That is, the biochar cansequester contaminants in a highly stable form, thereby reducing soilcontaminant uptake by plants. Biochar can also sequester nitrogen andmethane in the soil, thereby reducing emissions from the soil.

The biochar product can be applied to fields using conventionallyavailable machinery or equipment such as that used to apply fertilizer.The biochar can be mixed with manures, compost or fertilizers andincluded in the soil without additional equipment. Biochar has beenshown to improve the structure and fertility of soils, thereby improvingbiomass production, which can in turn be used in the pyrolysis processto generate more biochar.

While the benefits of biochar may depend to some extent on externalfactors, such as environmental conditions (e.g., temperature andhumidity) where the biochar product is being used, the specific benefitsof the biochar produced according to the systems and methods describedherein are at least somewhat dependent on the properties of the biocharitself. Accordingly, the systems and methods described herein may beused to specifically design biochar products to target various end-uses.

Before continuing, it is noted that as used herein, the terms “includes”and “including” mean, but is not limited to, “includes” or “including”and “includes at least” or “including at least.” The terms “managed” and“controlled” are used interchangeably to describe the kiln. The term“based on” means “based on” and “based at least in part on.”

FIGS. 1-8 illustrate various aspects of an example biochar kiln 100. Itis noted that the biochar kiln is not limited to the one shown in thefigures. Variations are also contemplated as being within the scope ofthe claims, as will be readily apparent to those having ordinary skillin the art after becoming familiar with the teachings herein.

In an example, the biochar kiln is a wood burning kiln. Feedstock may beburned in a combustion chamber within the kiln to provideself-sustaining energy such that no appreciable external heat is used.Trees and/or other biomass may be used as the feedstock.

In another example, biomass feedstock may be converted to char withexternal heating by, for example, gas, electricity, biomass heat sourcesor combinations thereof.

With particular reference to FIGS. 1 & 2, a kiln 100 includes a lid 110a drum 200 comprised of walls 230 and bottom 250. Lid 110 is formed tobe fitted to a top edge of drum walls 230 to close the top end of drumwalls 230 with lid 120 and form a combustion chamber between lid 110,walls 230, floor 250. As shown, lid 110 has a planar circular shape.However, lid 110 may take any of variety of shapes which allow arelatively close fit of lid 110 with drum walls 230. In some examples,lid 110 may be formed from a plurality of panel segments 120 (e.g.,eight panels, joined at adjacent side edges).

Lid 110 includes a lid flange 130 around its circumferential edge formedto fit over a top edge of drum walls 230. A gasket or other suitableretainer ring 132 may be provided around and separated from lid flange130 by spoke tabs 131 (e.g., a high temp gasket rope which is compressedbetween the lid edge and top flange of the drum). Guide plates 121extend from a top surface of lid 110. Two or more stack guide plates mayinclude through-holes for receipt of a pipe/bail bushing 122 for usewith lid bail 600, described in detail below. Chain plates 123 may alsobe formed to extend from top surface of lid 110 and include chain plateholes 124 configured to receive bail chains used to facilitate lifting.

A lid collar 140 is provided surrounding a central opening in lid 110. Alid stack valve plate 141, depicted in detail in FIG. 9, is fitted intothe central opening and includes radial openings 143 and center opening144. A lid seal ring 142 provided to a top surface of stack valve plate141 is designed to enhance the seal of stack valve plate 141 with lidcollar 140. In use, stack valve plate 141 regulates outlet of smoke fromthe combustion chamber through center opening 144. For example, lidstack valve plate 141 may be rotated between open positions in whichopenings 143 allow passage of exhaust and closed positions in whichopenings 143 are obstructed and prevent passage of exhaust. At anunderside of lid 110, lid centering guides 145 extend radially inwardfrom inner surface of lid collar 140 to meet with lid chimney sleeve 146provided for fitting with chimney 300.

The lid 110 is designed to mate with an upper end of drum 200 tocontribute to forming a combustion chamber as illustrated by way ofexample in FIGS. 3-5. Drum 200 includes walls 230 formed generally as acylinder having top and bottom ends. In the example illustrated, walls230 are a cylinder with a circular base. However, the base of walls 230may take any of a variety of shapes which allow for a relatively closefit with lid 110 and floor 250. In an example, walls 230 may beconstructed of a plurality of individual pieces. For example, twohalf-shells may be joined together during kiln assembly according to aprocess appropriate for the material of construction of the individualpieces. For example, if walls 230 are formed of metal, the pieces may bewelded together. A channel grab ring 210 (FIGS. 1 & 3-5) is formed on anexterior surface of drum 200 to facilitate gripping of kiln 100 by anautomated handler, as illustrated by way of example in FIG. 8. Channelgrab ring 210 may include upper 221 and lower 222 support rings to guidegrippers of an automated handler into a channel formed therebetween. Airinlet ports 240 are provided extending through walls 230 betweenexterior and interior sides to provide inlets for accepting regulatedairflow into the combustion chamber.

Air inlet ports 240 allow outside air to enter the combustion chamber tofeed the fire and may also be referred to as the primary air vents. Asanother function however, after initial firing of a kiln, anotherexothermic source, (e.g., propane “weed-burning” torches) may beinserted into each inlet port 240 to start a fire in each quadrant ofthe burn chamber. Air inlet ports 240 may be at least partially shieldedfrom the heat of the combustion chamber by shields 241.

As depicted by way of example in FIG. 2, floor 250 is formed to befitted to bottom edge of drum walls 230 to close the bottom end of drumwalls 230 and form the previously mentioned combustion chamber betweenbottom 250, walls 230 and lid 110. As shown, floor 250 has a planarcircular shape. However, floor 250 may take any of variety of shapes,which allow a relatively close fit of floor 250 with drum walls 230. Inan example, floor 250 may be formed from a plurality of panel segments251, for example eight panels, joined at adjacent side edges. Floor ribs252 are shown extending radially inward from the outer circumference offloor 250 to an air inlet pipe 270 extending through a center opening infloor 250.

Ribs 252 provide added structural integrity to floor 250. A bottom tieplate 260 is provided spaced apart from floor 250 by ribs 252. A stackmount plate 280 is also provided. In an example, bottom tie plate 260may be used to join the floor stiffeners. The bottom tie plate 260 mayalso be removed, for example, to add a center mounted blower air pipe orto reduce manufacturing costs.

An example is shown in FIGS. 3-5 wherein the floor may be sloped tofacilitate draining of liquid buildup from burning wet wood, and orinclude “wood vinegar” (derived from the wood, volatiles, and liquidcreosote). Low points on floor 250 may be substantially lined up withinlet air ports 240 to permit drainage of liquid from inside the kilnout through the air inlet ports 240.

A chimney 300 is depicted by way of example in FIGS. 3-6. Chimney 300may extend within the combustion chamber between the center opening offloor 250 and the center opening of lid 110 and out therethrough.Chimney 300 is configured for heating during pyrolysis and forexhausting smoke from the combustion chamber. As illustrated, chimney300 has a generally cylindrical shape and in use, a top portion ofchimney 300 may be mated to lid chimney sleeve 146 while a bottom end ispartially encompasses air inlet pipe 270 and is mated to chimney bottomplate 320.

In an example, chimney 300 includes exhaust inlet pipes 330 (alsoreferred to as scavenger pipes) configured to pass smoke and air fromthe combustion chamber to chimney 300. Centrally locating chimney 300with a plurality exhaust inlet pipes 330 serves to balance air intakefrom the plurality of air inlet ports 240. For example, when wind isblowing strong on one side of the kiln but not as strong on another,chimney 300 mixes air intake from across all of the inlets 330. Smoke isexhausted from the combustion chamber into chimney 300 up through uppersub-stack 350 (FIG. 25).

Kiln 100 may be manufactured of steel, other materials or combinationsthereof and may be designed to be disassembled, relocated, and thenreassembled or may be provided as a unitary structure. Kiln 100 may beconstructed to a variety of dimensions but may be, for example,approximately 1 m in height.

As depicted by way of example in FIG. 7, lid bail 600 may be hingedlyengaged with stack guide plates 121 by bushings 122 and bail pivot boltassembly 630 which may include a hex bolt, a nut and a washer. Bailchain plate 610 provides an opening for receipt of a bail chain forsecuring bail bar 620 to prevent pivoting of lid bail 600. Lid bail 600is provided to facilitate lifting of kiln lid 110 to remove lid 110 fromdrum 200 to open kiln 100.

Based at least in part on the feedstock characteristics, pyrolysis mayrelease carbon dioxide, black carbon, carbon monoxide, and othergreenhouse gases into the air in the form of smoke, contaminants, andodors. Therefore, for biochar production to work on a commerciallyviable scale, the kiln described herein may implement effective captureand mitigation techniques for the exhaust gases. As an alternative, orin addition thereto, a catalytic converter may be provided to reduce oraltogether eliminate smoke and/or odor emissions into the surroundingenvironment and/or atmosphere.

FIG. 10 illustrates a perspective section view of an example catalyticconverter 700 for use with biochar kiln 100. A catalytic converter 700(also referred to as a combustor or a secondary combustor) may beconfigured to fit within chimney 300 near center opening 140 of lid 110of biochar kiln 100, such that exiting smoke passes through catalyticconverter 700. In an example, more than one catalytic converter may beprovided as shown by way of example in FIG. 25.

As smoke from the combustion chamber passes through a catalyticconverter, the smoke particulate is incinerated at a high temperature(e.g., 926° C. or higher, and at least higher than the pyrolysistemperature), thus enabling the smoke itself to be incinerated prior tobeing emitted from the biochar kiln. As such, use of a catalyticconverter may help comply with government environmental standards. Forexample, using a catalytic converter may allow an installation tooperate a large number of kilns (e.g., 200 kilns or more at one site) atsubstantially the same time.

In an example, the catalytic converter 700 includes channels 710 as partof its internal chamber structure through which air (e.g., includingoxygen) and smoke (e.g., including hydrocarbons and other carbonbyproducts such as CO, NO₂/NO₃ and others) pass after entering catalyticconverter 700 from the combustion chamber. In an example, the exhaustincludes water vapor and CO₂ exiting on a downstream side of channels710.

Catalytic converter 700 may be made of any suitable material, such aschemically treated metals (e.g., depositions of Platinum and Palladium),ceramic, or combinations thereof. In an example, catalytic converter 700is formed as a disk measuring from approximately 15 to approximately 30centimeters (cm) in diameter, and from approximately 2.5 toapproximately 8 cm in thickness. However, catalytic converter 700 may beformed to have any of a variety of dimensions enabling it to fit wellwithin any outlet of the kiln 100.

Catalytic converter 700 is configured for operating conditions of thebiochar kiln with which it is used and is not limited to the structureshown but, instead, may adopt any of a variety of structures appropriatefor incinerating smoke produced in the combustion chamber. Catalyticconverter may take a variety of shapes.

Catalytic converters may operate optimally at controlled temperatures.

Temperatures may be controlled using preheating, or by waiting until thecombustion chamber is sufficiently heated on its own. When smoke is notsufficiently hot, supplemental heating may be used to preheat catalyticconverter 700. For example, the catalytic converter 700 may be preheatedto a desired temperature in a range of from approximately 176° C. toapproximately 871° C. before lighting kiln 100, for example, byinserting a propane torch into an opening near the bottom of thecatalytic converter.

In another example, catalytic converter 700 may be preheated using a(e.g., gas) furnace burner supplied within the combustion chamber nearcatalytic converter 700. This burner may be cycled on and off by acomputer.

For purposes of illustration, during operation, in light mode, a burneras described above is used to preheat catalytic converter 700 coretemperature to approximately 315° C. The pre-heat burner may be kept onuntil catalytic converter 700 reaches a temperature of greater thanapproximately 537° C.

The catalytic converter 700 may be maintained at the desired operatingtemperature throughout the burn and cook modes to facilitateincineration of smoke and emissions. If the temperature of the catalyticconverter 700 drops, the burner may be turned back on to keep catalyticconverter 700 smoke free. Quadrants of the combustion chamber may bedriven to equal temperatures using individual controls.

If heat generated in the combustion chamber of the biochar kiln and thesmoke is sufficiently hot, catalytic converter 700 may be operatedwithout any preheating.

Ending the pyrolysis at the appropriate time can be important to obtaindesired characteristics of the biochar product. Left to continue burninglonger, yield may be burned off. If the burning is shorter, undercookedbiochar may have lower adsorptive performance. Accordingly, a monitorand control subsystem may be implemented to help ensure optimal biocharproduct yield (e.g., product characteristics and/or product volume).

In an example, the monitoring subsystem may include a weight or masssensor. For example, the sensor may monitor mass of the biochar kiln.The monitored mass may be a gross weight, or a tarred mass (e.g., massof the product loaded into the kiln minus mass of kiln itself).Generally, the mass of the feedstock will decrease as the feedstock isconverted to biochar product. Accordingly, the sensor may be used todetect a predetermined mass indicating an optimal yield (e.g., that thefeedstock has completely converted to biochar product).

The catalytic converter(s) operate with a mixture of air and smokeparticles to operate efficiently. Too little oxygen and/or smoke, or toomuch can result in improper operation. In an example, about 8% oxygen isprovided into the catalytic converters during operation, and output ismeasured for about 2-3%. The difference indicates proper oxygen levelsare being consumed by the catalytic converter, and the catalyticconverter is not being starved for air. If there was 0% oxygen in theeffluent, then it would be difficult if not impossible to determinewhether the catalytic converters were consuming the proper amount. Thus,providing sufficient oxygen into the catalytic converters gives a goodindication that enough air is being consumed with very little surplus(which could result in belching smoke).

The temperature of a catalytic converter may drop when denied fuel (inthe form of smoke) or oxygen. When feedstock is cooking out excessiveorganic matter and moisture, there may be plenty of smoke to fuel thecatalytic converter. However, when the cooking stage begins to end (onlybiochar remaining), the amount of smoke is greatly reduced. As a result,the temperature of the catalytic converter may decrease due to a reducedfuel supply.

Considering the temperature changes, catalytic converter 700 may also beimplemented as part of a monitor and control subsystem to determine whenbiochar production is complete. Air temperature above catalyticconverter 700 may be monitored to detect a transition from a slowpyrolysis phase to a shut-down phase. The monitoring subsystem may be atany suitable location or distributed at various locations.

A temperature drop can be used as an indicator that the biocharconversion process is nearly complete. Accordingly, the temperature dropcan be detected, and a notification can be issued to alert an operatorthat biochar conversion at or near completion.

A monitor and control subsystem may include sensors to detect theseparameters and other operating conditions of a biochar kiln. In anexample as depicted in FIG. 11, a monitor and control subsystem mayinclude a temperature sensor 910 near catalytic converter 700 configuredto monitor temperature of smoke at any point(s) upstream and/ordownstream from the catalytic converter, temperature of the catalyticconverter or a combination of these.

Notification(s) may be transmitted by a transmitter 920 to a portableelectronic device 940, for example, in response to the catalyticconverter reaching threshold temperature(s) or a range of thresholdtemperatures. The notification(s) may be, for example, in the form of analarm or email issued to a plant operator using monitor and controlsubsystem 930 and may be sent locally and/or wirelessly to remotedevices such as smart phones or other electronic devices.

In an example, subsystem 930 may respond by automatically shutting downbiochar conversion in one or more biochar kilns.

A feedback loop may be provided as part of the monitor and controlsubsystem. Sensor output may be used by a programmable logic control(PLC) or other electronic control device. In an example, an averageoutput may be measured from each of the plurality of catalyticconverters. The monitored output may be used to check that operationstays in band (e.g. between two thresholds), and adjustments can be madeto control air, smoke or both for proper operation of the catalyticconverters. The feedback loop may mathematically assign parameters tooptimize the motor speed of blowers such as 345 and 590 (e.g., air flowor CFM), damper adjustments or both. In an example, aproportional/integral/derivative (PID) controller may be used tomaintain the air-to-smoke ratio within an acceptable range.

A computing subsystem may be used to monitor sensor measurements, e.g.,comparing measurements to pre-established threshold(s). In an example,the burn finish condition temperature (e.g., as measured above thecatalytic converter) is less than about 80% of normal operatingtemperatures (e.g., during cook mode) while the secondary air blower isoperating at near zero air flow.

Before continuing, it should be noted that the examples described aboveare provided for purposes of illustration, and are not intended to belimiting. Other system and/or device configurations may be utilized tocarry out the operations described herein.

FIG. 12 illustrates a flowchart showing example operations for processmonitor and control of a biochar kiln. The operations include, but arenot limited to, sensing temperature near a catalytic converter S1100,receiving exhaust from a combustion chamber of the biochar kiln andsensing a temperature in step S1100, comparing the monitored temperatureto a threshold in step S1200, the threshold indicating that thecatalytic converter has reached a threshold temperature; and issuing anotification in step S1300 in response to a catalytic converter reachingthe threshold temperature.

In an example, an auto-shutdown subsystem may be provided in step S1400to shut down the biochar conversion process even when the biochar kilnis unmanned. For example, automatic shutdown may be enabled bycompletely dosing air inlet ports 240, exhaust inlets 330, chimney 300or combinations thereof with mechanical or electro-mechanical actuatorsto operate shutters or dampers. In an example, sensors may indicate thecatalytic converter has decreased to at least 50% of an optimaloperating temperature. In an example, a notification issued by themonitor and control system may provide advance warning. In anotherexample, a monitor and control subsystem may detect operating phases ofa biochar kiln.

FIGS. 13 & 14 illustrate port covers 400 for the ventilation and exhaustsubsystem. Port covers 400 are visible in FIGS. 1, 4, 8, 27 & 28 aroundthe lower circumference of biochar kiln 100 and may be used to controlthe internal operating conditions. Port covers 400 enable dosing off airto the biochar kiln when the conversion process is completed, instead ofhaving to load dirt around the base of the biochar kiln to smother thepyrolysis. Accordingly, covers 400 eliminate the mess and dust oftenassociated with moving dirt around the kiln, in addition to reducinglabor and heavy equipment operation. Further, a biochar kiln may be usedeven when dirt is wet and muddy and/or frozen in colder environments.Because port covers 400 seal the combustion chamber, a kiln may be movedwithout having to wait for complete extinguishment thus enabling earlierand cleaner transport.

FIG. 14 is an exploded view showing components of an example port coverillustrated in FIG. 13. In this example, a high temperature siliconrubber gasket 440 may be compressed on an end of port pipe 240 into kiln100. A handle plate weldment 410 provided with fingers 411 and handles421, and in this example, a seal cover bolt assembly 420 provided withhex bolt 421, washer 422, nut 423 and self-locking nut 424. Cam surfaceson fingers 411 provide axial pressure to air inlet ports 240 as cover400 is rotated. Port covers 400 further include sealing cover centeringguide 430 having flanges 431, sealing cover backing plate 450 andsealing cover center plate 440.

With centering guide 430 and backing plate 450 sealing cover plate 440floats relative to the clamping cover so as to avoid scrubbing againstthe sealing surface of port 240 and thereby reduce wear on sealing coverplate 440. Furthermore, cover 400 is encouraged to find its naturalcenter while engaging with pins provided on the kiln exterior. Thiscompensates for the inevitable manufacturing tolerances of pin placementand cam surfaces. Thus, both pins are equally engaged and plate 440 ispressed flat against the sealing surface with equally distributedpressure.

In another example, a lead-in detail (not illustrated) on sealing coverplate 440 may be provided to further assist its centering on ports 240.This makes operation automatic so that the operator does not have tomanually drop it into the center position by feel of the fit.

As illustrated in FIGS. 15-28, in an example, an external flowregulation assembly 500 may be coupled with port covers 400 which are,in turn, coupled to collars of air inlet ports 240. Flow regulationassembly 500 provides a butterfly valve including a butterfly disc 570.Rotation of disc 570 about an axis through shaft 575 is enacted byservomotor 580. To completely prevent air flow from outside a kiln,through damper pipe 560 and into a kiln combustion chamber, disc 570 isrotated to a position where its surface normal-line is colinear with thelongitudinal axis of pipe 560. To allow maximum flow through pipe 560,disc 570 is rotated 90 degrees from the closed position. Servomotor 580is capable of rotating disc 570 to any of a variety of anglesintermediate between completely closed and completely open. A housing585 is provided to protect working components of servomotor 580.Further, a shield 567 may be provided between servomotor 580 and a kilnto which assembly 500 is coupled to offer additional protect ofservomotor 580 from the heat of the kiln combustion chamber.

A constant speed blower 590 may be provided at the outside end of damperpipe 560 for providing forced air regulated, in part, by assembly 500, acomputer controller or both. In another example, blower 590 may providevariable speeds without a damper. In yet another example, a damper maybe used without any blower.

Flow regulation assembly 500 can be monitored and controlled by a systemsuch as that illustrated in FIG. 11 to operate servomotors 580 to openand close the air inlet ports 240 based upon the output from one or moresensors 910. Air inlet ports 240 may be opened to provide additionaloxygen (e.g., at startup) and closed to reduce oxygen in the combustionchamber. Opening and dosing air inlet ports 240 may be immediate(open/close) or gradual during pyrolysis.

Independent control of the opening and dosing of air inlet ports 240allows an operator to provide local fire control in each quadrant. Ifthe overall fire is delivering too much heat, smoke or both to thechimney and catalytic converter, the operator can back off on the kilnfire. Furthermore, with multiple independently controllable air inletports 240, if one quadrant of the combustion chamber is burning toostrong, an operator or automated controller can limit air in thatparticular quadrant, increase air to the other quadrants or both to evenout the burn.

A threshold may be established to determine dosing or gradual closing ofair inlet ports with assembly 500. For example, an auto-shutdown system,as described above, may be provided to actuate assemblies 500 (e.g.,based on feedback from a temperature sensor, oxygen sensor, and/orweight sensor) and shut down the biochar conversion process even whenthe biochar kiln is unmanned. An auto-shutdown system may enable thebiochar conversion process to be stopped in sufficient time to reduce oreliminate unnecessary burning that would otherwise reduce quantityand/or quality of the yield. In another example, the feedback controlloop may issue a notification to a plant operator to manually controldamper 570 and blower 590.

As illustrated in FIGS. 29-32, in some example kiln systems, a firstforced air inlet 351 may be provided on chimney 300 above one or morecatalytic converters 700 to draw smoke through chimney 300 during apreheating stage. For example, a leaf blower or other blower may beconnected before chimney 300 is sufficiently hot to draw smoke uptherethrough on its own to “prime” chimney 300 while it heats up. In anexample, temperature, oxygen sensors or both may be provided andfeedback from these sensors may be used to actuate and deactivate ablower provided to forced air inlet 351.

A second forced air inlet 341 may operatively coupled with chimney 300at any point above or below the one or more catalytic converters 700.Second forced air inlet 341 may be provided to allow for adjusting theair/smoke mixture for optimal catalytic converter operation. Again, ablower 345 coupled with inlet 341 may be activated to increase airflowwhen air naturally occurring in the smoke stream is insufficient. Blower345 may be deactivated when there is sufficient air. Different blowerspeeds may be used on conditions in between. A diffuser, baffle, blade,angling, or other means may be provided inside chimney 300 to causemixing of the air through turbulence.

The temperature of catalytic converter 700 is controllable with thesecond forced air inlet 341 and blower 345. If the flow rate ofsecondary blower 345 is already at maximum and is unable to provideenough air to cool catalytic converter 700, air dampers 570 and blowers590 at a base of the kiln can be manually or automatically limited toreduce heat and smoke emitted from the combustion chamber and blower 345motor speed can be reduced.

As volatile organic and other compounds are purged from the feedstock,kiln smoke declines such that catalytic converter 700 requires lesssecondary air and the blower rate is reduced. When secondary blowerspeed declines a predetermined amount, the char conversion is deemed tohave been completed.

In an example, chimney 300 may include a motorized or manual damper toallow additional flow control. Such a damper may enable controlling theamount of smoke entering chimney 300 and can be used to preventoverwhelming catalytic converters 700 with smoke. As such, both air flowand smoke being exhausted can be controlled, for example, by operationof blowers for air flow, and dampers for smoke exhaust.

FIG. 33 illustrates a flow diagram of an example exhausting process.Feedstock may be loaded into the kiln and the loaded kiln may betransported to a “firing line”. With kiln prepared for pyrolysis, air isprovided through air inlet ports 240 to the combustion chamber in stepS3100. In an example including a plurality of air inlet ports, airintake is balanced through the plurality of air inlet ports to provideeven combustion within the kiln.

Combustion is initiated in the combustion chamber and smoke is exhaustedthrough chimney 300 in step S3200. Chimney 300 is thus heated bypyrolysis in the combustion chamber.

Pyrolysis burns feedstock in the combustion chamber during a cookingstage at temperatures in the range of from approximately 300° C. toapproximately 500° C. For example, the temperature of portions ofchimney 300 internal to kiln 100 may be about four times hotter than asmoke stack located at the outside of the side on the kiln (e.g., agradient of 538° C. versus 121° C.). This temperature gradient providesa draft of airflow into the combustion chamber from the air inlet ports,which forces the smoke out through the chimney. The catalytic converterelevates the exhaust or chimney temperature in the range of fromapproximately 315° C. to approximately 1093° C.

In scenarios wherein the temperature gradient between the lower part ofchimney 300 and the upper part of chimney 300 is not sufficient to drawexhaust through chimney 300 and catalytic converter 700, first forcedair inlet 341 may be used to prime the chimney 300 during a preheatingstage according to step S3300 and draw exhaust until a sufficienttemperature gradient has been reached. As illustrated in FIG. 34,operating conditions may be sensed according to step S3250 in order todetermine when chimney 300 should be primed in step S3300. Priming thechimney, for example with air inlet 341, may be performed in response tosensing operating conditions of the biochar kiln.

After the preheating stage, the chimney is sufficiently hot that theblower may be turned off, and smoke exhausts from the combustion chamberthrough the chimney, even in colder operating environments to reduce theamount of smoke exiting from the biochar kiln.

Once exhaust is flowing through chimney 300, exhaust emissions arecontrolled with one or more catalytic converters 700 in step S3400.

During operation of a biochar kiln, the air-to-smoke ratio is carefullycontrolled in step S3500 to ensure proper operation of the one or morecatalytic converters 700. As illustrated in FIG. 35, operatingconditions may be sensed according to step S3450 in order to properlycontrol the air/smoke mixture in step S3500. For control, air inlet portcovers 400 and assembly 500 are operated to open air inlet ports 240 toprovide air to the combustion chamber and to close air inlet ports 240to prevent air from entering the combustion chamber in step S3600. Asillustrated in FIG. 36, one or more operating conditions may be sensedin step S3550 in order to determine the appropriate time for closing ofair inlet ports 240 in step S3600.

Before continuing, it should be noted that the examples described aboveare provided for purposes of illustration, and are not intended to belimiting. Other devices and/or device configurations may be utilized tocarry out the operations described herein.

Use of one or more catalytic converters 700 as described above, alsoenables significant heat recovery for use in secondary applications. Asdescribed, the catalytic converter dramatically increases a fluetemperature (e.g., about 300%) of chimney 300 without adding more kilnfuel (e.g., wood biomass). This heat is available for externalharvesting and storage for later use. Applications which may benefitfrom the harvested heat may include oil sands hot water used to recoveroil from the sands, greenhouses, etc. The secondary subsystem may be anoil sands production water heater, a building heater, or a watercondenser or a combination of these. Another application may includeusing steam to condense air moisture to capture more useable water. Thisis particularly advantageous in the semi-arid areas containing oilsands.

Heat storage may be implemented using water or steam tanks or other heatstorage technology.

In an example illustrated in FIG. 37, A heat exchanger 1000 isconfigured to recover heat from chimney 300 and provide the heat to asecondary application. In an example, heat exchanger 1000 is configuredto exchange heat from one volume of air to another volume of air. In anexample, heat exchanger 1000 is configured to exchange heat from avolume of air to a volume of liquid. In an example, heat exchanger 1000is configured to exchange heat from a volume of air to a volume ofsteam. Heat exchanger 1000 is in thermal contact with the heat producedin chimney 300.

The above-described monitor and control subsystem may also be configuredto control the conditions of the combustion chamber based upon atemperature of a heat exchanger 1000 sensed by one or more sensors 910.A threshold may be used to indicate a temperature change (e.g., that thecatalytic converter has reached a predetermined temperature)corresponding with a conditions under which a heat exchanger can be madeoperational. A notification may be issued in response to the catalyticconverter changing to the predetermined temperature (or temperaturerange) so that proper steps can be taken to ensure heat from the heatexchanger does not adversely affect the secondary applications. Forexample, the notification may be in the form of an alarm issued to theplant operator and can be sent locally and/or wirelessly to remotedevices such as smart phones or other electronic devices so that otherheat sources may be brought online/offline to supplement heat from theheat exchanger.

As with previously discussed processes of operating biochar kilns, anoptimal mixture of smoke and air is controlled using an automated systemincluding sensors 900 for sensing operating conditions of the heatrecovery process. The mixture may be varied by operating forced airinlet(s) to control operating condition(s) of the catalytic converter(s)700 according to sensed operating conditions.

FIG. 38 illustrates a flow diagram of an example heat recovery process.In steps S4100 and S4200, a biochar kiln is operated to produce exhaustfrom a combustion chamber. The biochar kiln may be operated near asecondary application at a pyrolysis temperature below approximately537° C. for biochar production.

Exhaust from the combustion chamber is incinerated using one or morecatalytic converters in step S4300. Heat is recovered from theincinerated exhaust with a heat exchanger 1000 in step S4400. Heat maybe recovered by exchanging heat from a first volume of air to a secondvolume of air, exchanging heat from a volume of air to a volume ofliquid, exchanging heat from a volume of air to a volume of steam orcombinations of these.

After step S4400, heat may be stored according to step S4500 or provideddirectly to a nearby secondary operation in step S4600. Storing at leastsome of the heat from the stack temperature for later use may beaccomplished using an external water or steam tank or other heat storagetechnology.

The steps described above may be implemented as methods of operation. Byway of example, a method for ventilating and exhausting a biochar kilnmay comprise providing air through a plurality of air inlet ports to acombustion chamber; exhausting smoke through an internal chimneyprovided in the combustion chamber and controlling exhaust emissionswith at least one catalytic converter.

The method may further comprise heating the internal chimney bypyrolysis in the combustion chamber. The method may further comprisepriming the internal chimney in a preheating stage. Priming the internalchimney may further comprise operating a blower to force air into theinternal chimney and draw smoke through the internal chimney during thepreheating stage. Priming the internal chimney may further compriseoperating the blower in response to sensing operating conditions of thebiochar kiln. Providing air through a plurality of air inlet portsfurther may comprise balancing air intake through the plurality of airinlet ports.

The method may further comprise operating port covers to open the airinlet ports to provide air to the combustion chamber and to dose the airinlet ports to prevent air from entering the combustion chamber. Themethod may further comprise automatically controlling the port covers inresponse to sensing operating conditions of the biochar kiln. The methodmay further comprise operating a damper to control an air-to-smoke ratioin the internal chimney. Controlling an air to smoke ratio may furthercomprise operating a blower to control operating condition(s) of thecatalytic converter. Controlling an air to smoke ratio further comprisesoperating the blower in response to sensing conditions of the catalyticconverter.

An example heat recovery process may comprise operating a biochar kilnto produce exhaust from a combustion chamber; incinerating the exhaustwith a catalytic converter; recovering heat from the incinerated exhaustwith a heat exchanger; and providing the recovered heat to a nearbysecondary operation.

The process may further comprise maintaining an optimal smoke/airmixture with a controller. Maintaining an optimal smoke/air mixture mayfurther comprise sensing operating conditions of the heat recoveryprocess. Maintaining an optimal smoke/air mixture may further comprise,using the controller to operate a blower according to sensed operatingconditions.

In an example, recovering heat may further comprise exchanging heat froma first volume of air to a second volume of air. Recovering heat mayfurther comprise exchanging heat from a volume of air to a volume ofliquid. Recovering heat may further comprise exchanging heat from avolume of air to a volume of steam.

In an example, providing the recovered heat may further compriseproviding the recovered heat to one or more of an oil sands productionwater heater, a building heater, or a water condenser.

In an example, sensing operating conditions may further comprise furthercomprising at least one of sensing an exhaust temperature, sensing acatalytic converter temperature and sensing a heat exchangertemperature. The process may further comprise storing recovered heat.

The operations shown and described herein are provided to illustrateexample implementations. It is noted that the operations are not limitedto the ordering shown. Still other operations may also be implemented.

It is noted that the examples shown and described are provided forpurposes of illustration and are not intended to be limiting. Stillother examples are also contemplated.

1. A biochar kiln exhaust apparatus, comprising: a chimney configuredfor heating by pyrolysis and for exhausting smoke from the combustionchamber; and a plurality of exhaust inlet pipes configured to pass smokefrom the combustion chamber to the chimney.
 2. The apparatus of claim 1,further comprising at least one catalytic converter operatively coupledwith the chimney for reducing emissions from smoke exhausting throughthe chimney.
 3. The apparatus of claim 1, further comprising a damperassembly coupled with the chimney and configured to regulate exhaustflow therethrough.
 4. The apparatus of claim 1, further comprising afirst forced air inlet operatively coupled with the chimney to controlat least one operating condition of the at least one catalyticconverter.
 5. The apparatus of claim 4, further comprising a secondforced air inlet operatively coupled with the chimney to control atleast one operating condition of the at least one catalytic converter.